Inflatable thermal packaging structure with multiple liners

ABSTRACT

A packaging structure includes an outer shell and a first inflatable liner attached to an interior surface of the outer shell. Air chambers of the first inflatable liner are in fluid communication with a valve. The packaging structure can also include a second inflatable liner attached to the first liner. Air chambers of the second inflatable liner are in fluid communication with the valve.

CROSS REFERENCES TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional PatentApplication No. 61/328,101, filed on Apr. 26, 2010, the disclosure ofwhich is hereby incorporated by reference in its entirety for allpurposes.

BACKGROUND OF THE INVENTION

Packaging of materials is utilized in a variety of industries. Despitethe progress made in packaging technology, there is a need in the artfor improved methods and systems related to packaging of products.

SUMMARY OF THE INVENTION

Embodiments of the present invention relate to packaging technology. Ina particular embodiment, a packaging structure includes a firstthermally insulating, inflatable liner to provide thermal protection fortemperature sensitive and/or perishable products after inflation of theliner. The packaging structure may also include a second liner toprovide a cushioning layer as an option to protect the products frommechanical shock. In a specific embodiment, a single valve is used toinflate both liners concurrently.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a simplified seal pattern illustrating a shape for the seallines for the first liner illustrated in FIG. 4.

FIG. 2 illustrates a rigid or hard outer shell.

FIG. 3 illustrates the first liner inserted inside the hard outer shell.

FIG. 4 illustrates the hard outer shell and the first liner in an openedformat.

FIG. 5 illustrates the glue point between the first line and the hardouter shell.

FIG. 6 illustrates the first liner in a non-inflated state.

FIG. 7 illustrates examples of perimeter heat seals.

FIG. 8 illustrates a series of discontinuous heat seals to form thefolding line.

FIG. 9 illustrates the first liner (thermal liner) and the second liner(cushioning chamber) in a non-inflated state.

FIG. 10 illustrates the packaging structure after inflation.

FIG. 11 illustrates a thermal liner in a box formed after inflation.

DETAILED DESCRIPTION OF THE INVENTION

According to an embodiment of the present invention, a box is lined withmultiple liners. A first liner that provides thermal insulation uponinflation can be an Airliner, available from the present assignee. TheAirliner provides thermal protection for temperature sensitive and/orperishable products after inflation of the Airliner. The box could alsobe lined with a second liner that provides cushioning to absorb shocks.

According to embodiments of the present invention, a method is providedthat is characterized by a process of forming one “rigid” thermal boxvia the inflation of the Airliner through a valve or entry point using,for example, a single step, eliminating one or more of the steps offorming the box, taping the bottom of the box, inserting the liner afterinflation after folding the gussets, and the like. FIG. 1 illustratesthe shape of the seal lines for the first liner illustrated in FIG. 4.Embodiments of the present invention are not limited to the particularshape and dimensions illustrated in FIG. 1.

A hard outer shell made of materials that provide mechanical rigidity isillustrated in FIG. 2. The hard outer shell can be made of corrugatedpaper such as e-flute, f-flute, or the like. The hard outer shell can besingle or double wall as appropriate to the particular application.Although a paper-based hard outer shell is illustrated in FIG. 2, thehard outer shell can be corrugated or formed from a solid plastic.Embodiments of the present invention are not limited to the particularshell illustrated in FIG. 2.

FIG. 3 illustrates the first liner as it is inserted in the hard outershell and fixing the position of the first liner. The position of thefirst liner is fixed by gluing, taping, or the like so that the shelland the first liner form a single unit.

FIG. 4 illustrates the hard outer shell and the first liner in an openedformat. As illustrated in FIG. 4, the shape of the first liner isselected to provide a predetermined shape that may not cover all theportions of the hard outer shell. Embodiments of the present inventionare not limited to the particular shape illustrated in FIG. 4. The firstliner is pre-shaped by a series of heat seals for perimeter and foldinglines to determine the final form after inflation. When the outer shellis folded together, the areas of the outer shell not provided with thefirst liner, overlap to provide for a single layer of the first linerinside the folded outer shell. The first inflatable liner for thermalinsulation can be made using one or several films, including, but notlimited to, LDPE, HDPE, Nylon, Surlyn, or the like.

As illustrated in FIG. 4, an embodiment of the present inventionprovides a hard outer shell with an inflatable liner attached to aninterior portion of the hard outer shell. This embodiment can be providefor thermal insulation and some degree of mechanical cushioning forobjects stored or shipped in the package. A valve is provided to inflatethe first liner. In a particular embodiment, inflation of the firstliner results in semi-automatic formation of the package as the airchambers in the liner inflate and take shape, providing pressure toconstruct the outer shell. One of ordinary skill in the art wouldrecognize many variations, modifications, and alternatives. Thus,embodiments of the present invention include a cardboard box with aninflatable liner attached at one or more points inside the cardboardbox. This combination box/liner can be provided to customers to enableeconomical packaging of objects benefiting from thermal insulation.Since the liner is assembled and shipped in a non-inflated condition,space savings are provided by embodiments of the present invention incomparison with other techniques.

FIG. 5 illustrates the glue point between the first line and the hardouter shell. The illustrated glue point is just an example and does notlimit the present invention.

FIG. 6 illustrates the first liner in a non-inflated state. FIG. 7illustrates examples of perimeter heat seals, which can be formed in acontinuous or discontinuous manner. An example of discontinuous heatseals is illustrated in FIG. 8, where heat seals are formed to form thefolding line.

In order to provide for both thermal insulation and mechanicalinsulation against shocks, dropping of the package, and the like, asecond liner is provided to provide cushioning for the products storedin the package. FIG. 9 illustrates the first liner (thermal liner) andthe second liner (cushioning chamber) in a non-inflated state. Thesecond liner is typically attached to the first liner at one or moreattachment points using tape, double-sided tape, glue, or the like.

FIG. 10 illustrates the packaging structure after inflation. Because ofthe integration of the multiple liners and the hard outer shell,inflation of the first inflatable liner and the second inflatable linerresult in an action similar to an automatic formation of the packagingproduct. The folded lines align with the corner of the hard outer shelland the seal lines define the extent of the air chambers.

The liner for the cushioning chamber can be made using one or severalfilms, including, but not limited to, LDPE, HDPE, Nylon, Surlyn, or thelike. It is sealed or laminated to the first (thermal) liner. In orderto provide for ease of assembly, both liners are inflated concurrently(e.g., at the same time) through a single valve or inflation entrypoint. Thus, a packaging product is provided that can be delivered as anintegrated product, requiring only filling at a single valve to providefor both thermal and mechanical insulation.

Although embodiments of the present invention illustrated herein utilizeboth the first inflatable liner and the second inflatable liner insidethe hard outer shell, other embodiments utilize only a single inflatableliner to provide thermal insulation for products stored or packaged inthe packaging structure. FIG. 11 illustrates a thermal liner in a boxformed after inflation. One of ordinary skill in the art would recognizemany variations, modifications, and alternatives.

1. A packaging structure comprising: an outer shell; a first inflatableliner attached to an interior surface of the outer shell, wherein airchambers of the first inflatable liner are in fluid communication with avalve; a second inflatable liner attached to the first inflatable liner,wherein air chambers of the second inflatable liner are in fluidcommunication with the valve.
 2. The packaging structure of claim 1wherein the outer shell is rigid.
 3. The packaging structure of claim 1wherein the outer shell comprises at least one of a cardboard or plasticmaterial.
 4. The packaging structure of claim 1 wherein the firstinflatable liner comprises at least one of a nylon, or plastic material.5. The packaging structure of claim 1 wherein the first inflatable linercomprises a plurality of heat seals defining the air chambers.
 6. Thepackaging structure of claim 5 wherein the air chambers of the firstinflatable liner are a single chamber having multiple sections.
 7. Thepackaging structure of claim 1 wherein the first inflatable liner isattached to the interior surface of the outer shell using a plurality ofglue strips.
 8. The packaging structure of claim 1 wherein the secondinflatable liner is attached to the first inflatable liner by at leastone of tape of glue.
 9. The packaging structure of claim 1 wherein thesecond inflatable liner is disposed inside the first inflatable linerupon inflation.
 10. A method of forming a thermal structure, the methodcomprising: providing a packaging structure including an outer shell;flowing a fluid through a valve to inflate a first inflatable linerattached to an inner surface of the outer shell; and flowing the fluidthrough the valve to inflate a second inflatable liner attached to thefirst inflatable liner.
 11. The method of claim 10 wherein the fluidcomprises air.
 12. The method of claim 10 wherein the outer shell isrigid.
 13. The method of claim 10 wherein the outer shell comprises atleast one of a cardboard or plastic material.
 14. The method of claim 10wherein the first inflatable liner comprises at least one of a nylon, orplastic material.
 15. The method of claim 10 wherein the firstinflatable liner comprises a plurality of heat seals defining the airchambers.
 16. The method of claim 10 wherein the air chambers of thefirst inflatable liner are a single chamber having multiple sections.17. The method of claim 10 wherein the first inflatable liner isattached to the interior surface of the outer shell using a plurality ofglue strips.
 18. The method of claim 10 wherein the second inflatableliner is attached to the first inflatable liner by at least one of tapeof glue.
 19. The method of claim 10 wherein the second inflatable lineris disposed inside the first inflatable liner upon inflation.